Inductive conductivity sensor and method

ABSTRACT

The disclosure includes an inductive conductivity sensor for measuring the specific electrical conductivity of a medium with a transmitter coil energized by an input signal, a receiver coil coupled with the transmitter coil via the medium, which receiver coil supplies an output signal that is a measure for the conductivity of the medium, and a housing enclosing the transmitter coil and the receiver coil, which housing comprises at least one housing section designed to be immersed in the medium, the housing wall of said housing section surrounding the transmitter coil and the receiver coil. The housing is made of a magnetic plastic or resin for inductively decoupling the transmitter coil from the receiver coil. In certain embodiments, the housing may be made of a ferromagnetic material. Another aspect of the disclosure includes a method for manufacturing the conductivity sensor.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present divisional application is related to and claims the prioritybenefit of U.S. patent application Ser. No. 15/170,436, filed on Jun. 1,2016 and German Patent Application No. 10 2015 108 613.1, filed on Jun.1, 2015, the entire contents of which are incorporated herein byreference.

TECHNICAL FIELD

The present disclosure relates to an inductive conductivity sensor formeasuring the specific electrical conductivity of a medium and to amethod for the production of the same.

BACKGROUND

The measurement of the specific electrical conductivity is used forcontrolling process engineering processes. In food technology, forexample, product streams in pipes are differentiated from cleaningsolutions or rinsing water by means of the measurement of the specificelectrical conductivity. Depending upon certain media, processengineering processes are also influenced.

In general, conductivity sensors that work according to an inductive ora conductive measurement principle are often used in the processautomation to measure the electrical conductivity of a medium. Aconductive conductivity sensor comprises at least two electrodes thatare immersed in a medium in order to take measurements. In order todetermine the electrical conductivity of the medium, the resistance orconductance of the electrode measuring path in the medium is determined.If the cell constant is known, the conductivity of the medium can thenbe determined. In order to measure the conductivity of a measuring fluidby means of a conductive conductivity sensor, it is absolutely necessarythat at least two electrodes come into contact with the measuring fluid.

With the inductive principle of determining the conductivity of processmedia, sensors are used that comprise both a transmitter coil and areceiver coil arranged at a distance from the transmitter coil. By meansof the transmitter coil, an alternating electromagnetic field isproduced, which affects charged particles, e.g., ions, in the liquidmedium and generates a corresponding electric current in the medium. Asa result of this electric current, an electromagnetic field is generatedat the receiver coil, inducing a received signal (induction voltage) inthe receiver coil according to Faraday's law of induction. This receivedsignal can be analyzed and used to determine the electrical conductivityof the liquid medium.

Inductive conductivity sensors are typically designed as follows. Thetransmitter coil and the receiver coil are generally built as toroidalcoils and comprise a continuous opening through which the medium canflow. The coils are arranged in a housing which is immersed in themedium to be measured. The medium thus flows around both coils. Theexcitation of the transmitter coil creates in the medium a closedcurrent path that passes through both the transmitter coil and thereceiver coil. By analyzing the current and voltage signals of thereceiver coil in response to the signal from the transmitter coil, theconductivity of the measuring fluid can be determined. The principle initself is established in industrial process measurement technology andhas been documented in a large number of texts in the patent literature.

The coils consist of at least one winding of a conductor made of a wirethat is wound on a coil carrier and provided with a magnetic core. Thewinding arrangement and winding form, the diameter of the wire, thewinding material, and the core material define the value of therespective inductance and additional (quality) characteristics of thecoil.

High-quality coils and cores are often used for conductivity sensors.These coils have a low temperature dependency because the relativepermeability of the coils or the cores exhibits a low temperaturedependency. Even in cores of very high quality, however, a certaintemperature dependency exists, whether because of slow drift due toaging or at high temperatures, e.g., above 130° C. Relativepermeabilities that change over time or with the temperature affect themeasured value and thus the measured conductivity.

Often, conductivity sensors have additional functions that are alsoperformed based upon alternating electromagnetic fields. For example,measurements of the flow rate, the pressure, or the density should bementioned here. These additional functions can, however, only beperformed one after the other because the magnetic and electrical fieldsinfluence one another.

BRIEF SUMMARY

At least one aspect of the present disclosure includes an inductiveconductivity sensor for measuring the specific electrical conductivityof a medium with a transmitter coil energized by an input signal, and areceiver coil coupled with the transmitter coil via the medium. Thereceiver coil supplies an output signal that is a measure for theconductivity of the medium. A housing encloses the transmitter coil andthe receiver coil, and the housing includes at least one housing sectiondesigned to be immersed in the medium. A housing wall of the housingsection surrounds the transmitter coil and the receiver coil. Thehousing includes a magnetic—especially a ferromagnetic—plastic or resininductively decoupling the transmitter coil from the receiver coil. Thehousing is surrounded by or insert-molded with a plastic that isdifferent from the magnetic plastic. The inductive sensor furtherincludes a circuit board with conductor paths and an extensive groundplane, where the ground plane is designed to capacitively decouple thetransmitter coil and the receiver coil from the conductor paths. Thecircuit board is arranged between the transmitter coil and the receivercoil, and the transmitter coil and the receiver coil are in contact withthe circuit board. The circuit board includes a temperature sensor whichis arranged outside of the housing.

The inductive conductivity sensor also includes at least one cover madeof a magnetic, especially a ferromagnetic, plastic or resin, where thecover closes the transmitter coil and/or the receiver coil. In certainembodiments, the inductive conductivity sensor includes additionalsensors—in particular, pressure sensors and flow rate sensors—and thehousing has recesses for these additional sensors.

Another aspect of the disclosure includes a method for manufacturing theconductivity sensor disclosed herein using the following steps:manufacturing a housing made of a magnetic, in particular aferromagnetic, plastic or resin; mounting at least one transmitter coiland one receiver coil in the housing; insert-molding the housing with anadditional plastic that is different from the magnetic plastic; andarranging the transmitter coil and the receiver coil on a circuit board;and insert-molding the circuit board.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a conductivity sensor according to exemplary embodiments ofthe present disclosure.

FIGS. 2A and 2B show cross-sectional views of a housing of aconductivity sensor according to exemplary embodiments of the presentdisclosure.

FIG. 3A shows an inductive coupling of a conductivity sensor housingaccording to exemplary embodiments of the present disclosure.

FIG. 3B shows a capacitive coupling of a conductivity sensor housingaccording to exemplary embodiments of the present disclosure.

FIG. 4 shows a conductivity sensor according to exemplary embodiments ofthe present disclosure.

In the Figures, the same features are marked with the same referencesymbols.

DETAILED DESCRIPTION

The present disclosure provides an adaptable conductivity sensor thattakes measurements in a manner that is stable in the long term and withrespect to the temperature. The present disclosure includes an inductiveconductivity sensor characterized in that its housing comprises amagnetic plastic or resin for inductively decoupling the transmittercoil from the receiver coil. In certain embodiments, the plastic orresin material may be a ferromagnetic material. Thus, an inductivedecoupling of the coils from one another occurs. The coupling betweenthe two coils is an unwanted component of the measured value. In orderto determine the measured value correctly, this coupling must bedetermined and reconciled against the measured value, i.e., reduced.Since the coupling essentially depends upon the relative permeability,and since the latter is, as mentioned, temperature dependent, thetemperature dependency of the conductivity sensor can be reduced bydecoupling the coils from one another.

In food processing technology and biotechnology, there are requirementsthat the sensors are able to be sterilized thermally and designed to becleaned well (i.e., hygienic design). As a matter of principle,inductive conductivity sensors must at least in part consist of anelectrical insulating material. Plastic is generally used for thispurpose. These plastics require a special approval for use in the areaof food technology and biotechnology.

In one advantageous embodiment, the housing is therefore surrounded by aplastic that is different from the magnetic plastic. In certainembodiments, the magnetic portion of the housing may be insert-moldedwith the different material.

In order to reduce the capacitive coupling, the conductivity sensorcomprises a circuit board with conductor paths and an extensive groundplane, wherein the ground plane is designed for this capacitivedecoupling of the transmitter coil and the receiver coil from theconductor paths, wherein the circuit board is arranged between thetransmitter coil and the receiver coil, and the transmitter coil and thereceiver coil are in contact with the circuit board. The circuit boardmay include a temperature sensor that is arranged outside the housing.

In one advantageous further development, the conductivity sensorcomprises at least one cover made of a magnetic—in particular,ferromagnetic—plastic or resin, wherein the cover closes the transmittercoil and/or the receiver coil. The cover further reduces the stray fieldof the coils. The cover comprises a non-conducting ring, wherein thesmall non-conducting ring prevents a short circuit between turns of thecoils from occurring. At the same time, this cover serves as protectionagainst mechanical influences.

In one preferred embodiment, the conductivity sensor comprisesadditional sensors—in particular, pressure sensors and flow ratesensors—and the housing comprises recesses for these additional sensors.As a result of the magnetic as well as, if applicable, capacitivedecoupling, measurements can be taken by the additional sensors at thesame time and without interference.

The present disclosure further includes a method for the production of aconductivity sensor as described above, comprising the following steps:Manufacturing a housing made of a magnetic—in particular,ferromagnetic—plastic or resin; mounting at least one transmitter coiland one receiver coil in the housing; and insert-molding the housingwith a plastic that is different from the magnetic plastic. In at leaston embodiment, the transmitter coil and the receiver coil are arrangedon a circuit board, and the circuit board is insert-molded with plastic.

For the purposes of promoting an understanding of the principles of thepresent disclosure, reference will now be made to the embodimentsillustrated in the drawings, and specific language will be used todescribe the same. It will nevertheless be understood that no limitationof the scope of this disclosure is intended, with any additionalalterations, modifications, and further applications of the principlesof this disclosure being contemplated hereby as would normally occur toone skilled in the art. Accordingly, this disclosure is intended tocover alternatives, modifications, and equivalents as may be includedwithin the spirit and scope of this disclosure as defined by theappended claims. While this technology may be illustrated and describedin a preferred embodiment, the systems, methods, and techniques hereofmay comprise many different configurations, forms, materials, andaccessories.

An inductive conductivity sensor 1 according to at least one embodimentof the present disclosure is shown in FIG. 1. The conductivity sensor 1may be use in process automation. The conductivity sensor 1 may bearranged—for example, via a flange 4 (generally via a processconnection)—on a vessel 3 in which the medium 2 to be measured islocated. The vessel 3 may be a pipe made, for example, of plastic ormetal.

The conductivity sensor 1 comprises a transmitter coil 6 and a receivercoil 7 that are located inside a housing 9. The housing 9 comprises ahousing wall 16. The housing 9 is manufactured from a plastic—inparticular, a thermoplastic. In certain embodiments, the plastic may beone approved for use in the area of food technology and biotechnology.For example, the plastic may be a polyaryl ether ketone such aspolyetheretherketone (PEEK) as described further below.

The transmitter coil 6 and the receiver coil 7 are arranged, forexample, opposite one another on sides of a circuit board (not shown)that face away from one another. In this way, the transmitter coil 6 andreceiver coil 7, which are designed as rotation-symmetric toroidal coils(“toroids”), are arranged coaxially, one behind the other. The circuitboard comprises the conductor paths that contact the coils and connectthe transmitter coil 6 with a driver circuit, and the receiver coil 7with a receiver circuit. The driver circuit and the receiver circuit canform part of the sensor circuit installed on the circuit board. Thecoils 6, 7 are connected with a data processing unit 5 in FIG. 1, with ameasuring transducer.

The housing 9 forms a channel 12 that passes through the transmittercoil 6 and the receiver coil 7 along their axes of rotation. If thehousing 9 is immersed in an electrically conductive medium 2, the mediumsurrounds the housing 9 or a housing section 8 designed to be immersedin the medium 2 and enters the channel 12, so that, in the medium, aclosed current path 13 passing through both coils 6, 7 can form when thetransmitter coil 6 is excited or flowed through by an input signal,i.e., an alternating voltage.

The conductivity sensor functions in the manner of a double transformer,wherein the transmitter and the receiver coils 6, 7 are inserted asmentioned into the medium 2 to at least the extent that a closed currentpath 13 running through the medium 2 and passing through the transmitterand the receiver coils 6, 7 can be formed. When the transmitter coil 6is excited with an alternating voltage signal used as an input signal,it generates a magnetic field which induces a current path 13 whichpasses through the coils 6 and 7 and the strength of which depends uponthe electrical conductivity of the medium 2. Thus, a current path withan ionic conduction results in the medium 2. Since this alternatingelectrical current in the medium in turn generates a varying magneticfield that surrounds it, an alternating current is induced in thereceiver coil 7 as an output signal. This alternating current and thecorresponding alternating voltage respectively, which are delivered bythe receiver coil 7 as output signal, are a measure of the electricalconductivity of the medium 2.

The conductivity sensor 1 comprises a temperature sensor 10 formeasuring the temperature of the medium 2. The data processing unit 5determines the conductivity of the medium 2 based upon the input signal,the output signal, and the temperature of the medium 2. The temperaturesensor 10 is an electrical or electronic component that supplies anelectrical signal as a measure for the temperature. The component is,for example, a negative temperature coefficient thermistor (NTCthermistor) or a positive temperature coefficient thermistor (PTCthermistor), the resistance of which changes with the temperature.Examples in this regard are platinum measuring resistors or ceramic PTCthermistors. Alternatively, a component may be used that directlysupplies a processable electrical signal, such as, for example, asemiconductor temperature sensor that supplies a current or voltageproportional to the temperature. As additional alternatives, athermocouple or other common temperature measuring element may be used.

The temperature sensor 10 comprises a temperature element that suppliesan electrical signal as a measure for the temperature. This is, forexample, a thermistor, such as a Pt100 or Pt1000. Via wires 18, thissignal—such as, for example, resistance values or a voltage—istransmitted to the measuring transducer 5.

FIGS. 2A and 2B shows a cross section of the housing 9 of theconductivity sensor 1. The housing 9 comprises a magnetic—in particular,ferromagnetic—plastic or a magnetic—in particular, ferromagnetic—resinfor inductively decoupling the transmitter coil 6 from the receiver coil7. Examples of magnetic plastics are Luvocom 1105-9096, Ferrotron®, orFluxtrol®. The magnetic material is used to inductively decouple thecoils 6, 7 from one another; see also FIG. 3B. The magnetic resinincludes resin mixtures with magnetic filler materials. A coldmanufacturing method is thus possible, whereby the magnetic fillermaterials better maintain their magnetic properties. Resins are alsoeasily insert-molded (see below).

The housing 9 is surrounded by a plastic that is different from themagnetic plastic. In one embodiment, the housing is insert-molded. Themanufacturing method for the conductivity sensor 1 is then as follows:manufacturing the housing 9, mounting at least one transmitter coil 6and one receiver coil 7 in the housing 9, and insert-molding the housing9 with the plastic that is different from the magnetic plastic.

The housing 9 may be designed as a milled part or an injection part, asa complete carrier, or as a plug-in unit made of several parts. In oneembodiment, in case of an injection part or a plug-in part, a circuitboard 11 may be placed between the coils 6, 7 as an insert that isinsert-molded with them. The circuit board 11 may be a star or flexcircuit board. The coils 6 and 7 are in contact with the circuit board11. For this purpose, the circuit board 11 comprises conductor paths(not shown) for connecting the coils 6 and 7 with the already mentionedmeasuring transducer 5. The circuit board 11 comprises a large groundplane 17. This ground plane 17 reduces the capacitive coupling of thecoils 6 and 7 with the conductor paths on the circuit board 11.

The coils 6, 7 are covered by a cover 14. With the exception of a smallnon-conducting ring 15, this cover 14 consists of the already discussedmagnetic plastic or magnetic resin. The cover 14 further reduces thestray field of the coils 6, 7. The non-conducting ring 15 prevents ashort circuit between turns of the coils 6, 7. At the same time, thiscover 14 serves as protection against mechanical influences.

In FIG. 2B, the circuit board 11 is extended downward and equipped withthe temperature sensor 10; i.e., the temperature sensor 10 is positionedoutside the housing 9 in this embodiment. Provided with a protectingcap, the temperature sensor may also be insert-molded later.

FIG. 3A shows the capacitive decoupling. The circuit board 11 interruptsthe capacitive coupling K, illustrated by arrows. The interruption isillustrated with dashed lines. The capacitive coupling between the coils6 and 7 and the conductor paths of the circuit board 11 is reduced bythe grounded, largely mounted, ground plane 17 of the injected orembedded circuit board 11.

FIG. 3B shows the inductive decoupling. The inductive coupling M,illustrated by arrows, is interrupted by means of the magnetic materialof the housing 9. The interruption is illustrated with dashed lines.Stray fields which occur are absorbed by the magnetic housing 9.

In conductivity sensors with additional integrated functions,measurements can be performed only one after the other, since themagnetic and electric fields influence one another. For this reason, inFIG. 4, various sensor elements are integrated into a common housing andmagnetically and capacitively shielded as described above. In aninductive conductivity sensor 1 comprising a housing 9 consisting of amagnetic plastic or resin, recesses 19 for additional sensors 20—forexample, inductive sensors or sensors that function according to otherprinciples—are applied at any positions in the same housing 9, inaddition to the usual coils 6, 7. These recesses 19 may comprise, forexample, magnetic flow rate sensors, pressure sensors, or other sensors.The magnetic plastic prevents mutual interactions between the inductivecoils 6, 7 and the various additional sensors 20. The contact is alsoestablished via wires 18—for example, in conduits—up to the circuitboard 11. The additional sensors 20 are also hygienically insert-moldedby a plastic other than the magnetic plastic.

While various embodiments of a inductive conductivity sensor and methodsof making the same according to the present disclosure have beendescribed as having an illustrative design, the present disclosure maybe further modified within the spirit and scope of this disclosure. Thepresent application is therefore intended to cover any variations, uses,or adaptations of the invention using its general principles. Further,the present application is intended to cover such departures from thepresent disclosure as come within known or customary practice in the artto which this invention pertains.

Further, in describing representative embodiments, the presentdisclosure may have presented a method and/or a process as a particularsequence of steps. However, to the extent that the method or processdoes not rely on the particular order of steps set forth therein, themethod or process should not be limited to the particular sequence ofsteps described, as other sequences of steps may be possible. Therefore,the particular order of the steps disclosed herein should not beconstrued as limitations of the present disclosure. In addition,disclosure directed to a method and/or process should not be limited tothe performance of their steps in the order written. Such sequences maybe varied and still remain within the scope of the present disclosure.

The invention claimed is:
 1. A method for manufacturing an inductiveconductivity sensor, comprising: manufacturing a first portion of ahousing from a magnetic plastic or a magnetic resin material; insertinga transmitter coil and a receiver coil in the first portion of thehousing; insert-molding a second portion of the housing from a plasticor resin material that is different from the magnetic plastic or themagnetic resin of the first portion, wherein the second portion of thehousing at least partially surrounds the first portion.
 2. The method ofclaim 1, wherein the magnetic plastic of the first portion of thehousing is a ferromagnetic plastic.
 3. The method of claim 1, furthercomprising: providing a circuit board having conductor paths and aground plane, wherein the ground plane is designed to capacitivelydecouple the transmitter coil and the receiver coil from the conductorpaths of the circuit board; arranging the transmitter coil and thereceiver coil on the circuit board such that the transmitter coil andthe receiver coil are in electrical contact with the circuit board; andinsert-molding the circuit board with a plastic or resin material thatis different from the magnetic plastic or the magnetic resin of thefirst housing portion.
 4. The method of claim 3, further comprising:arranging a temperature sensor on the circuit board, whereininsert-molding the circuit board includes insert-molding the temperaturesensor.
 5. The method of claim 3, wherein the circuit board is soembodied that a portion of the circuit board extends outside the firstportion of housing, the method further comprising: arranging atemperature sensor on the portion of the circuit board that extendsoutside the first portion of the housing; and providing protecting capover the temperature sensor.
 6. The method of claim 1, wherein themagnetic resin of the first portion of the housing is a ferromagneticresin material.